[gss036]

I am seriously thinking about getting the kit and doing my fuel pump. Looks like a simple job. Do you use all the parts that are shown/listed in the kit? I read something in one of the post about making sure you change the right one(diaphragm)?. I see that there appears to be 2 in the kit. Any help would be appreciated.The reason for the rebuild is a slow die at idle, pump up the prime bulb and it is fine. I ran in some 3-4 ft chop yesterday and seemed to be getting a little surge at 3000-3400, but really hard to tell in heavy chop and 20-25 mph wind, but tried to die on me when flushing. I checked and I haven't changed the fuel/water sep filtercsince February, so I got one on the back of the boat now to change. It is possible I could have water build up in the filter. That could easily cause some surge in choppy water. I run off of a 115 gallon onboard tank.

[rodbolt]

hello the pump is simple. carefully disassemble the old one. match the new gaskets and diaphrams to the old and go for it. good luck and remember, pumps dont last forever

[PinchiPancho]

The kits are easy to assemble. I have an 89 100hp and I serviced the fuel pump recently with a fuel pump kit... you don't always use all the parts in the kit...they usually make kits to fit more than one fuel pump so they include verious diaphrams... Do as rodbolt suggested, match the diaphrams to the old. Good luck

[gss036]

Thanks for the input, The kit is on order w/Mercury Express parts. $10.26 + shipping, cheap enough.Do you need to completely remove the pump from the block? Disconnecting the fuel lines or just uncrew the screws and pull out the parts? I probably should pick up some clamps for the hoses.I think they showed up at about 15 cents each.

[gss036]

I got an e-mail from Mercury today, the parts are back ordered a few days, -out of stock. No one jumped in here for the this question, can anyone help me out here?"Do you need to completely remove the pump from the block? Disconnecting the fuel lines or just uncrew the screws and pull out the parts?"

[davejohnson]

In my '78 Merc 900 inline 6, you can't "remove the pump from the block", you only remove the top, as the bottom is molded into the block itself. I just rebuilt my fuel pump and it was a breeze. One rubber diaphram, sandwiched between two gaskets, replace the two check valves and the cone-shaped screen strainer and o-ring, and boom, you're done. One piece of advice, make sure the o-ring on the strainer on top is seated properly, you may have to monkey with it. You'll know if it's wrong if you start spraying fuel from that area. Oh, and I replaced the 'zip-tie' that was holding my fuel line with a steel hose clamp. Tighten everything snug and you're done.

[gss036]

Thanks Dave for jumping in. I have not tried to remove the pump yet. I will wait until I have the new one in hand. It looks simple enough either way as the pump is at eye level standing by the motor.I get that done, I may just go ahead and do the thermostasts as they are orginal also and very easy access.

[gss036]

I got tired of waiting and called the Mercury dealer yesterday and sure enough, my parts had arrived and sitting on the shelf for sale w/o notifying me. At any rate I picked it up and installed it today. Not to hard to do, instructions not as clear as they could be. The motor runs great. The old parts showed wear but still in tact and no holes anywhere.RODBOLDT!!! Question for you please. The instruction sheet said disgard all the inside parts to include the neopreme seals under the plastic check valves and it shows reassembly w/o them. Is that correct or should I have saved the neopreme seals and put them under the little round plastic check valve??.

[gss036]

>>RODBOLDT!!! Question for you please. The instruction sheet said disgard all the inside parts to include the neopreme seals under the plastic check valves and it shows reassembly w/o them. Is that correct or should I have saved the neopreme seals and put them under the little round plastic check valve??.

[rodbolt]

nope the neoprene is old stuff. the new style check valves are just tiny plastic discs. did ya have fun seperating the lock pins from the locks . anyway I told ya it was fairly simple. good luck and keep posting

[gss036]

One of the lock pins was easy, just drove it back through, the other one took a little more effort.Yes, it was simple compared to rebuilding a 4 barrel carb.